Vehicle ventilator and speed control resistor circuit therefor

Abstract: A blower motor speed control resistor array (40) includes resistor elements (28,32,36) formed by multiple optimally sized patches (42-46) of resistive ink deposited onto opposite sides of a thin flat ceramic substrate (48). The array (40) comprises three resistive patches (42-46) connected in series via fuse elements (62,64,82,98) to provide three reduced blower motor speeds MH, M and L. The thin ceramic substrate (48) is flat on both of its faces, and each face comprises a terminal region (110) for attachment of the resistive patches (42-46) to terminal elements (114-120), and a resistor region for deposition of the three resistive patches (42-46). The resistive patch (42) of lowest resistivity (the MH resistor) is deposited on the entire resistor region of a first side of the substrate (48). The resistor patches (44,46) of intermediate and highest resistivities (the M and L resistors, respectively) share the resistor region of the other side of the substrate (48) in relation proportion to their respective resistivities.

Description: This invention relates to a speed control resistor circuit for a vehicle blower motor of a vehicle ventilator and to a vehicle ventilator. In automotive blower motor installations, several discrete blower speeds are customarily achieved through the use of various resistor elements connected in series with the blower motor via a multi-position speed control switch. In such installations, the resistor elements may be formed in an array on a support structure disposed in the inlet or discharge air path of the blower to dissipate heat generated by the passage of motor current through the resistor elements. The resistor elements may be discrete (wire-wound, for example) or printed in an array on a substrate in the manner of a printed circuit board. In US-A-5,000,662, for example, the resistors are formed from a serpentine pattern of resistive material deposited on a porcelain enamelled metallic substrate. A fundamental engineering trade-off occurs in the design of a resistor array due to conflicting cost, heat transfer and packaging considerations. For packaging considerations, the resistor array should be as small as possible. This also tends to minimise noise and airflow restriction in the air duct. For heat transfer considerations, the array should be designed to maximise heat rejection. In addition to materials selection, this consideration affects the package size and shape since heat rejection increases with increasing surface area. Of course, cost considerations tend to dictate against the use of exotic materials and complex manufacturing processes. The current design philosophy in blower motor resistor arrays is to incorporate a metallic element into the array in order to provide adequate heat rejection while keeping the size of the array reasonably small. In US-A-5,000,662, for example, porcelain enamel coating is deposited over a metal substrate. In other designs, a metallic fin is attached to the array. These designs may satisfy heat transfer and packaging considerations, but adversely affect cost considerations. The present invention seeks to provide an improved resistor circuit. According to an aspect of the present invention, there is provided a speed control resistor circuit for a vehicle blower motor of a vehicle ventilator as specified in claim 1. Preferably, there is provided a blower motor speed control resistor array in which the resistor elements are formed by multiple optimally sized patches of resistive material deposited onto both front and reverse sides of a thin, flat ceramic substrate. In the preferred embodiment, the array comprises three resistive patches connected in series via fuse elements, thereby providing three reduced blower motor speeds, referred to herein as medium-high (MH), medium (M), and low (L). Terminal elements connect one end of the array to the motor, and a selector switch selectively connects none, one, two or three of the resistive patches in the motor current path. In this embodiment, both front and reverse faces of the substrate have a terminal region for electrically coupling the resistive patches to the terminal elements, and a resistor region for deposition of the three resistive patches. The resistive path of lowest resistivity (the MH resistor) is deposited on the entire resistor region of a first side of the substrate. The resistor patches of intermediate and highest resistivities (the M and L resistors, respectively) share the resistor region of the other side of the substrate in relation to their respective resistivities. Electrical connection between resistor patches on the front and back sides of the substrate are advantageously made through a terminal element which contacts conductive terminal pads on both sides of the substrate. In MH blower operation, only the MH resistor is active. In this case, the motor current and blower speed are relatively high, and heat is rejected from the entire resistor region of the first side of the array. In M blower operation, both the MH and M resistors are active. In this case, the motor current and blower speed are somewhat reduced, and heat is rejected from both the entire resistor region of the first side and a portion of the resistor region of the second side. In L blower operation, all three resistors are active. In this case, the motor current and blower speed are relatively low, and heat is rejected from the resistor regions of both sides of the array. In the above manner, the entire available surface of the ceramic substrate can be sectored into three resistive patches having areas sized in relation to the maximum expected operating temperatures for each of the three modes, resulting in optimally uniform heat rejection during operation of the blower motor. The uniformity can maximise the heat rejection for a given array size, and can minimise the incidence of hot spots. This can permit closer proximity of the array to materials sensitive to elevated temperatures, and can therefore simplify packaging. Preferably, fuse elements are formed on the substrate for interrupting one or more of the resistor circuit connections if the substrate temperature rises above a predefined threshold. The uniform heat rejection characteristic of the array can contribute to consistent and reliable operation of the fuse elements in that the fuse elements are subject to substantially the same thermal conditions as the resistor patches. The resistor array of the preferred embodiments is advantageously formed with economical materials and a simple manufacturing process, while the size and placement of the resistive patches can optimise the heat rejection for a given package size, as noted above. The result can be a cost effective design having significant package size and heat rejection advantages. According to another aspect of the present invention, there is provided a speed control resistor circuit as specified in claim 4. According to another aspect of the present invention, there is provided a vehicle ventilator as specified in claim 6. An embodiment of the present invention is described below, by way of example only, with reference to the accompanying drawings, in which: Figure 1 is a schematic diagram of a conventional automotive blower motor control including a three-resistor array for speed control of the blower motor; Figures 2a and 2b are partial sectional views of the front and back sides, respectively, of a preferred embodiment of resistor array; Figure 3 is a sectional view of the resistor array of Figures 2a and 2b, taken along line 3-3 of Figure 2a; Figure 4 is an equivalent circuit of the resistor array of Figures 2a, 2b and 3; and Figure 5 is a thermal representation of the resistor array of Figures 2a, 2b and 3. Figure 1 shows a conventional vehicle blower motor control system including a storage battery 10, a key-operated ignition switch 12, a fuse 14, an operator manipulated fan speed selector switch 16, a resistor array 18, a DC fan motor 20 and a motor driven impeller 22. In the illustrated example, the positive terminal of battery 10 is connected to supply current to fan motor 20 via ignition switch 12, fuse 14 and selector switch 16. Alternately, the selector switch may be connected in the low side of the circuit; that is, between motor 20 and the negative terminal of battery 10. The selector switch 16 is positioned by the operator to control the speed of fan motor 20 by controlling the resistance of the motor current path. When the selector switch 16 engages the contact 24, as depicted in Figure 1, the battery voltage is directly applied to the fan motor 20 for full speed operation. When the contact 26 is engaged, the current path of fan motor 20 includes the MH (medium-high) resistor 28. When the contact 30 is engaged, the current path of fan motor 20 includes both the MH and M (medium) resistors 28 and 32. When the contact 34 is engaged, the current path of fan motor 20 includes the MH, M and L (low) resistors 28, 32 and 36. As the series resistance in the motor current path increases, the current supplied to the motor 20, and hence its speed of rotation, decreases. As indicated above, the resistor array 18 and impeller 22 are mounted in a blower motor air duct (not shown) so that the air flow produced by rotation of the impeller 22 augments the heat rejection of the array 18. The embodiment of resistor array shown in Figures 2a, 2b and 3 includes integral fusing, as described below, but otherwise is electrically equivalent to the resistor array 18 of Figure 1. Referring to Figures 2a, 2b and 3, the embodiment of resistor array 40 shown includes resistor elements 28, 32 and 36 created by forming three patches 42, 44 and 46 of electrically resistive material directly on a flat ceramic substrate 48. Figure 2a depicts a first side of the substrate 48, referred to herein as the front side, while Figure 2b depicts a second side, referred to herein as the reverse side. A single large surface area patch 42 corresponding to the resistor 28 of Figure 1 is formed on the front side, as seen in Figure 2a, and two successively smaller patches 44 and 46 corresponding to the resistors 32 and 36 of Figure 1 are formed on the reverse side as seen in Figure 2b. The patches 42, 44 and 46 are underlaid by a network of metallic strips which distribute and collect current, such strips being contiguous with a number of metallic pads which facilitate fusing and coupling to electrical terminals. Referring to Figure 2a, it can be seen that the patch 42 is underlaid by a first set of metallic strips 50, 52 contiguous with a terminal pad 54, and a second set of metallic strips 56, 58 contiguous with terminal pad 60 via fuse elements 62, 64, and metallic strip 66. Referring to Figure 2b, the patch 44 is similarly underlaid by a first set of metallic strip 70, 72 contiguous with a terminal pad 74 via metallic strip 76, and a second metallic strip 78 contiguous with terminal pad 80 via fuse element 82 and metallic strip 84. The patch 46 is underlaid by a first set of metallic strips 86, 88, 90 contiguous with terminal pad 92, and a second set of metallic strips 94, 96 contiguous with terminal pad 80 via fuse element 98 and metallic strip 84. As best seen in the sectional view of Figure 3, the fuse elements 62, 64, 82 and 98 consist of short lengths of metal band, soldered in tension between a pair of metallic pads formed on the substrate 48. The fuse function occurs if the temperature of the substrate 48 or environment rises above the melting point of the solder, whereupon the respective fuse element(s) returns to its pre-tensile state, interrupting the respective resistor connections. Referring to Figure 2a, the fuse elements 62, 62 are formed by a single metal band soldered to metallic strips 56 and 66, and to an intermediate metallic pad 100. Referring to Figure 2b, the fuse elements 82 and 98 are formed by a single metal band soldered to metallic strips 78, 84 and 96. A connector assembly 110 for forming an electrical connection with the resistor elements 28, 32 and 36 comprises a plastics housing 112 and four clip terminals 114-120 secured therein. As best seen in Figure 3 in relation to clip terminal 118, the clip terminals 114-120 are formed with integral fingers which contact both sides of the substrate 48. Thus, the clip terminal 114 contacts the terminal pads 60 and 74; the clip terminal 116 contacts the terminal pads 80 and 122; the clip terminal 118 contacts the terminal pads 92 and 124; and the clip terminal 120 contacts the terminal pads 54 and 126. The clip terminals may perform dual functions: interfacing the resistor array 40 to the selector switch 16, and electrically interconnecting the front and reverse sides of the substrate 48 (via pads 60 and 74) to facilitate the series connection of resistors on the front and reverse sides. The electrical equivalent circuit of the resistor array 40 is depicted in Figure 4. The resistor element connection points are identified by the reference numerals 54, 60/74, 80 and 92 assigned to the respective terminal pads. Figure 5 is a thermal representation of the front side of the resistor array 40 during MH (medium-high) operation of the blower motor 20. Not only is the surface temperature significantly lower than with known metallic processes, but the temperature distribution is much more uniform as well. The uniform temperature distribution and cooler operating temperatures reflect the more efficient heat transfer achieved with the described embodiment of array. Also, the uniform temperature distribution can ensure that the fuse elements 62, 64, 82, 98 and the respective resistor elements 42, 44, 46 operate at substantially the same temperature, contributing to better circuit protection. In an alternative embodiment, the M resistor could occupy all of the front side of the substrate, with the L and MH resistors occupying the reverse side of the substrate. Furthermore, a different fuse design could be employed, or the design could incorporate a different number of resistor patches.

Claims: A speed control resistor circuit for a vehicle blower motor of a vehicle ventilator comprising a flat ceramic substrate (48) including first and second sides, each side including a resistor region; a first resistor (28) formed by a first patch (42) of resistive material disposed on substantially the entire resistor region of the first side of the substrate; a second resistor (32) formed by a second patch (44) of resistive material disposed on a first portion of the resistive region of the second side of the substrate; and a third resistor (36) formed by a third patch (46) of resistive material disposed on a second portion of the resistor region of the second side of the substrate, the second and third portions comprising substantially the entire resistor region of the second side of the substrate. A speed control resistor circuit according to claim 1, wherein the first and second sides of the ceramic substrate include terminal regions on which are formed a series of conductive terminal pads (60,74), and the resistor includes fuse elements (62,64,82,98) disposed on the first and second sides of the substrate in the resistor regions thereof, the fuse elements being connected in circuit paths electrically coupling the resistors to the terminal pads. A speed control resistor circuit according to claim 2, comprising a series of terminals (114-120) electrically coupled to the resistors via the terminal pads, at least one of the terminals including a first contact electrically coupled to a terminal pad formed on the first side of the substrate and a second contact electrically coupled to a terminal pad formed on the second side of the substrate, said at least one terminal forming an electrical bridge between the first and second sides of the substrate. A speed control resistor circuit for a vehicle blower motor of a vehicle ventilator comprising a flat ceramic substrate (48) including first and second sides, each side including a terminal region on which is formed a series of conductive terminal pads (60,74) and a resistor region on which is formed at least one resistor (28-36), each resistor being formed by a patch (42-46) of resistive material disposed on a respective side of the substrate, each resistor being electrically coupled to a pair of terminal pads formed on a respective side of the substrate; and a series of terminals (114-120) electrically coupled to the resistors via the terminal pads, at least one of the terminals including a first contact electrically coupled to a terminal pad formed on the first side of the substrate and a second contact electrically coupled to a terminal pad formed on the second side of the substrate, said at least one terminal forming an electrical bridge between the first and second sides. A speed control resistor circuit according to claim 4, including a plurality of fuse elements (62,64,82,98) disposed on the first and second sides of the substrate in the resistor regions thereof, the fuse elements being connected in circuit paths electrically coupling the resistors to the terminal pads. A vehicle ventilator including a blower motor, a speed control resistor circuit according to any preceding claim coupled to a power supply path to the motor and a speed selector switch (16) for coupling one or more of the resistors of the resistor circuit between the power supply path and the blower motor. A vehicle ventilator according to claim 6, wherein the resistor circuit is disposed in an air duct of the ventilator.

Inventors: GOUBEAUX RONALD JOSEPH, ZIRNHELD RICHARD ANTHONY, GOUBEAUX, RONALD JOSEPH, ZIRNHELD, RICHARD ANTHONY
Applicants: GEN MOTORS CORP, GENERAL MOTORS CORPORATION
Application year: 1994
Main classification: H01C1
IPC codes: B60H1